Helmet with floating shell plates

ABSTRACT

A football helmet comprises a plastic shell having a recess formed in the shell, a shock absorbing pad in the recess and removably connected to the shell, and a floating shell plate removably attached to the shock absorbing pad and further connected to the shell by a tab-slot engagement. The helmet may further comprise an inner liner comprising a shock absorbing element, an inflatable liner element, and a mobility layer disposed between the shock absorbing element and the inflatable liner element, the mobility layer having a plurality of raised elements formed therein to separate the shock absorbing element from the mobility layer thereby forming a gap between the shock absorbing element and the mobility layer, enabling relative movement of the inflatable liner with respect to shock absorbing element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 62/576,467, filed Oct. 24, 2017, the disclosure of which isincorporated herein by reference in its entirety and for any and allpurposes as if fully set forth herein.

This application is also a continuation-in-part of U.S. application Ser.No. 29/606,636, filed Jun. 6, 2017, the disclosure of which isincorporated herein by reference in its entirety and for any and allpurposes as if fully set forth herein.

This application is also a continuation-in-part of U.S. application Ser.No. 29/616,447, filed Sep. 6, 2017, the disclosure of which isincorporated herein by reference in its entirety and for any and allpurposes as if fully set forth herein.

FIELD AND BACKGROUND OF THE INVENTION

The subject technology relates to a protective helmet for sports play,such as a football helmet, hockey helmet, lacrosse helmet, or the like.The subject technology is suitable for use in full-contact sports, suchas football, hockey, and lacrosse.

SUMMARY OF THE INVENTION

According to the subject technology, a helmet, such as a football helmetcomprises a durable shell formed of a suitable material such aspolycarbonate or acrylonitrile butadiene styrene plastic, adapted toreceive and protect the head of a wearer. The helmet includes ashock-absorbing system including removable liner components attached tothe inner surface of the shell; additionally, shock-absorbing elementsare associated with the outer surface of the shell. In an embodiment ofthe subject technology, recesses are formed in the outer surface of theshell to receive shock-absorbing elements. Floating shell plates areprovided over the shock-absorbing elements. In an embodiment of thesubject technology, a crown recess contains a shock-absorbing cushion orsheet of thermoplastic polyurethane (TPU) material in whichshock-absorbing elements are formed by molding. A floating shell plateis removably secured in contact with the peaks of the shock-absorbingelements. The floating shell plate has integral tabs formed thereinwhich engages with niches or slots formed in the outer shell andassociated with the crown recess. The floating shell plate is movableindependently of the helmet shell in in a direction normal to thesurface of the shell, and may be movable in a direction tangential tothe helmet shell and in the normal and tangential directions incombination. A rear recess with its corresponding shock-absorbing TPUsheet and floating shell plate of similar construction is also provided.

Additionally, the subject technology is directed to a helmet linersystem having relatively rigid shock absorbing elements attached to aninner surface of the shell, inflatable liner elements in contact withthe wearer's head, and mobility layers interposed between the shockabsorbing elements and inflatable liner elements. The mobility layersallow the inflatable liner elements to slip relative to the shockabsorbing elements and have some degree of motion independent of theshock absorbing elements which are connected to the shell. Thus, whenthe helmet is subjected to a blow or force during sports play,acceleration of the shell is not entirely transmitted to the wearer'shead.

Additionally, the subject technology is directed to a hybrid innerpadding assembly for a helmet, including a helmet for a full-contactsport, such as football, comprising a molded TPU shock absorber havingfrustoconical projections extending from a base sheet, mated with a padof molded foam material, the frustoconical projections being receivedsnugly into openings formed in the pad of molded foam material.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

FIG. 1 is a left, top, perspective view of a football helmet shellaccording to the subject technology.

FIG. 2 is a front elevational view of a football helmet shell accordingto the subject technology.

FIG. 3 is a rear elevational view of a football helmet shell accordingto the subject technology.

FIG. 4 is a right side elevational view of a football helmet shellaccording to the subject technology.

FIG. 5 is a left side elevational view of a football helmet shellaccording to the subject technology.

FIG. 6 is a top plan view of a football helmet shell according to thesubject technology.

FIG. 7 is a bottom plan view of a football helmet shell according to thesubject technology.

FIG. 8 is a plan view of a helmet according to the subject technologywith floating shell plate removed showing shell cushions installed tothe helmet.

FIG. 9 is a plan view of a helmet according to the subject technology.

FIG. 10 is a front view of a partially-assembled helmet according to thesubject technology.

FIG. 11 is a rear view of a helmet according to the subject technology.

FIG. 12 is a left side view of a helmet according to the subjecttechnology.

FIG. 13 is a bottom view of a partially assembled helmet according tothe subject technology.

FIG. 14 is a sectional view of a partially assembled helmet according tothe subject technology.

FIG. 15 is a partially exploded view of the crown area of a helmetaccording to the subject technology.

FIG. 16 is a rear perspective view of shock absorbing elements disposedon the inner surface of a helmet according to the subject technology.

FIG. 17 is a plan view of a floating shell plate according to thesubject technology.

FIG. 18 is a side view of a floating shell plate according to thesubject technology.

FIG. 19 is a cross-section view of a floating shell plate according tothe subject technology.

FIG. 20 is a perspective view of a floating shell plate according to thesubject technology.

FIG. 21 is a plan view of a floating shell plate according to thesubject technology.

FIG. 22 is a cross-section view of a floating shell plate according tothe subject technology.

FIG. 23 is a plan view of a shell cushion according to the subjecttechnology.

FIG. 24 is a cross-section view of a shell cushion according to thesubject technology.

FIG. 25 is a perspective view of a shell cushion according to thesubject technology.

FIG. 26 is a perspective view of a shell cushion according to thesubject technology.

FIG. 27 is a plan view of a shell cushion according to the subjecttechnology.

FIG. 28 is a detail view of ridges of the shell cushion of FIG. 27according to the subject technology.

FIG. 29 is a perspective view of a front area shock absorbing elementaccording to the subject technology.

FIG. 30 is a bottom view of a front area shock absorbing elementaccording to the subject technology.

FIG. 31 is a cross-sectional view of a front area shock absorbingelement according to the subject technology.

FIG. 32 is a top view of a front area shock absorbing element accordingto the subject technology.

FIG. 33 is a rear view of a front pad according to the subjecttechnology.

FIG. 34 is a cross-sectional view of a front pad according to thesubject technology.

FIG. 35 is a perspective view of a front pad according to the subjecttechnology.

FIG. 36 is a rear view of a front pad assembly according to the subjecttechnology.

FIG. 37 is a front view of a front pad assembly according to the subjecttechnology.

FIG. 38 is a front view of a front pad assembly according to the subjecttechnology, inside the comfort layer fabric.

FIG. 39 is a rear view of a front pad assembly according to the subjecttechnology, inside the comfort layer fabric.

FIG. 40 is a rear view of a lateral assembly of shock absorbing elementsaccording to the subject technology.

FIG. 41 is a rear view of a central element of a lateral assembly ofshock absorbing elements according to the subject technology.

FIG. 42 is a cross-sectional view of a central element of a lateralassembly of shock absorbing elements according to the subjecttechnology.

FIG. 43 is a right side view of a central element of a lateral assemblyof shock absorbing elements according to the subject technology.

FIG. 44 is a rear view of a top element of a lateral assembly of shockabsorbing elements according to the subject technology.

FIG. 45 is a cross-sectional view of a top element of a lateral assemblyof shock absorbing elements according to the subject technology.

FIG. 46 is a left side view of a left wing of a lateral assembly ofshock absorbing elements according to the subject technology.

FIG. 47 is a rear view of a left wing of a lateral assembly of shockabsorbing elements according to the subject technology.

FIG. 48 is a cross-sectional view of a left wing of a lateral assemblyof shock absorbing elements according to the subject technology.

FIG. 49 is a rear view of a right wing of a lateral assembly of shockabsorbing elements according to the subject technology.

FIG. 50 is a cross-sectional view of a right wing of a lateral assemblyof shock absorbing elements according to the subject technology.

FIG. 51 is a right side view of a right wing of a lateral assembly ofshock absorbing elements according to the subject technology.

FIG. 52 is a rear view of a lateral mobility layer according to thesubject technology.

FIG. 53 is a side view of a lateral mobility layer according to thesubject technology.

FIG. 54 is a front view of a lateral mobility layer according to thesubject technology.

FIG. 55 is a perspective view of an inflatable lateral liner accordingto the subject technology.

FIG. 56 is a front view of an inflatable lateral liner according to thesubject technology.

FIG. 57 is a rear view of an inflatable lateral liner according to thesubject technology.

FIG. 58 is a side view of an inflatable lateral liner according to thesubject technology.

FIG. 59 is a detail view of an inflatable cell of an inflatable lateralliner according to the subject technology.

FIG. 60 is a cross sectional view of an inflatable lateral lineraccording to the subject technology.

FIG. 61 is a front view of the assembly of a lateral mobility layer toan inflatable lateral liner according to the subject technology.

FIG. 62 is a side view of the assembly of a lateral mobility layer to aninflatable lateral liner according to the subject technology.

FIG. 63 is a plan view of the assembly of the lateral TPU assembly,lateral mobility layer, and inflatable lateral liner of the subjecttechnology.

FIG. 64 is a plan view of the assembly of the lateral TPU assembly,lateral mobility layer, and inflatable lateral liner of the subjecttechnology.

FIG. 65 is a detail view of the assembly of the lateral TPU assembly,lateral mobility layer, and inflatable lateral liner of the subjecttechnology.

FIG. 66 is a detail view of the assembly of the lateral TPU assembly,lateral mobility layer, and inflatable lateral liner of the subjecttechnology, showing how the valve assembly of the inflatable lateralliner is assembled through the keyway in the lateral TPU assembly.

FIG. 67 is a perspective view of a crown shock absorbing elementaccording to the subject technology.

FIG. 68 is a bottom view of a crown shock absorbing element according tothe subject technology.

FIG. 69 is a cross-sectional view of a crown shock absorbing elementaccording to the subject technology.

FIG. 70 is a top view of a crown shock absorbing element according tothe subject technology.

FIG. 71 is a front view of a crown mobility layer according to thesubject technology.

FIG. 72 is a rear view of a crown mobility layer according to thesubject technology.

FIG. 73 is a side view of a crown mobility layer according to thesubject technology.

FIG. 74 is a front view of a crown lateral liner according to thesubject technology.

FIG. 75 is a cross-sectional view of a crown lateral liner according tothe subject technology.

FIG. 76 is a perspective view of the assembly of a crown inflatableelement, crown mobility layer, and crown shock absorbing elementaccording to the subject technology.

FIG. 77 is a perspective view of the assembly of a crown inflatableelement, crown mobility layer, and crown shock absorbing elementaccording to the subject technology.

FIG. 78 is a top view of a face guard twist-release mount according tothe subject technology.

FIG. 79 is a cross-sectional view of a face guard twist-release mountaccording to the subject technology.

FIG. 80 is a front view of a face guard twist-release mount according tothe subject technology.

FIG. 81 is a cross-sectional view of a face guard twist-release mountaccording to the subject technology.

FIG. 82 is a rear view of a face guard twist-release mount according tothe subject technology.

FIG. 83 is a right side view of a right outer brace for a cheek supportaccording to the subject technology.

FIG. 84 is a left side view of a right outer brace for a cheek supportaccording to the subject technology.

FIG. 85 is a front view of a right outer brace for a cheek supportaccording to the subject technology.

FIG. 86 is a cross-sectional view of a right outer brace for a cheeksupport according to the subject technology.

FIG. 87 is a right side view of a left outer brace for a cheek supportaccording to the subject technology.

FIG. 88 is a left side view of a left outer brace for a cheek supportaccording to the subject technology.

FIG. 89 is a front view of a left outer brace for a cheek supportaccording to the subject technology.

FIG. 90 is a cross-sectional view of a left outer brace for a cheeksupport according to the subject technology.

FIG. 91 is a view of the outer face of an inner plate for a right cheeksupport

FIG. 92 is a view of the inner face of an inner plate for a right cheeksupport

FIG. 93 is a view of the outer face of an inner plate for a left cheeksupport

FIG. 94 is a view of the inner face of an inner plate for a left cheeksupport

FIG. 95 is a plan view of a left side cheek pad for a cheek supportaccording to the subject technology.

FIG. 96 is a bottom view of a left side cheek pad for a cheek supportaccording to the subject technology.

FIG. 97 is a plan view of a right side cheek pad for a cheek supportaccording to the subject technology.

FIG. 98 is a bottom view of a right side cheek pad for a cheek supportaccording to the subject technology.

FIG. 99 is a plan view of a pad of resilient polymer foam material whichmay be disposed in the inflatable cells of the inflatable linersaccording to the subject technology.

FIG. 100 is a plan view of a pad of resilient polymer foam materialwhich may be disposed in the inflatable cells of the inflatable linersaccording to the subject technology.

FIG. 101 is a plan view of a pad of resilient polymer foam materialwhich may be disposed in the inflatable cells of the inflatable linersaccording to the subject technology.

FIG. 102 is a top view of a shock absorbing element having a densedistribution of cones according to the subject technology.

FIG. 103 is a side view of a shock absorbing element having a densedistribution of cones according to the subject technology.

FIG. 104 is a cross-sectional view of a shock absorbing element having adense distribution of cones according to the subject technology.

FIG. 105 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 106 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 107 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 108 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 109 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 110 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 111 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 112 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 113 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 114 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 115 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 116 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 117 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 118 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 119 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 120 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 121 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 122 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 123 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 124 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 125 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 126 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 127 is a front view of a face guard for attachment to a helmetaccording to the subject technology.

FIG. 128 is a left side view of a face guard for attachment to a helmetaccording to the subject technology.

DETAILED DESCRIPTION OF THE DRAWINGS

As shown for example in FIGS. 1-6, helmet 1 shell according to thesubject technology comprises a shell 10 composed of a suitable materialsuch as polycarbonate, reinforced fiberglass, carbon fiber composite, oracrylonitrile butadiene styrene (ABS) plastic. Preferably the materialof shell 10 is strong enough to resist impacts but retaining someflexibility. Shell 10 may be manufactured by means known to those ofskill in the art including thermoplastic injection molding andthermoforming. Shell 10 has bilateral symmetry about a plane of symmetryP bisecting shell 10. Shell 10 has a front area, left area, right area,and rear area. Shell 10 has a front edge 29, left edge 30, right edge31, and bottom edge 32. Edges 29-31 define a face opening of shell 10.Left and right edges 30 and 31 meet bottom edge 32 at curved transitionsto define a left earflap 33 and right earflap 34 of a conventional type,size and extent known to the art, in the left area and right arearespectively. Shell 10 may be formed as two molded hemispheres,particularly a left hemisphere and a right hemisphere which are joinedtogether along the plane of symmetry P.

Notable features of shell 10 according to the subject technology arerecesses formed in the shell, which according to an embodiment are lyingin and bisected by plane of symmetry P, which are adapted to containshock absorbing elements covered by floating shell plates, ashereinafter described.

Crown recess 12 is formed in shell 10 for receiving crown shockabsorbing pad or cushion 70 and crown floating shell plate 60 ashereinafter described. Crown recess 12 has floor 14 defined by frontbank 15, rear bank 16, left bank 17, right bank 18. Banks 15-18 arepreferably formed to slope at an obtuse angle from the outer surface ofthe surrounding shell 10 to floor 14. Alternatively, banks 15-18 areformed to slope at a right angle, or approximately a right angle. Eachof banks 15-18 may have formed therein one more niches or through-goingslots. In the embodiment of FIGS. 1-6, front bank 15 has twothrough-going slots 19 and rear bank 16 has two through-going slots 20.Preferably, crown recess 12 is bisected by plane P and has bilateralsymmetry about plane P.

Rear recess 21 is formed in shell 10 for receiving rear shock absorbingpad 70 and crown floating shell plate 80 as hereinafter described. Rearrecess 21 has floor 22 defined by front bank 23, rear bank 24, left bank25, right bank 26. Banks 23-26 are preferably formed to slope at anobtuse angle from the outer surface of the surrounding shell 10 to floor22. Alternatively, banks 23-26 are formed to slope at a right angle, orapproximately a right angle. Each of banks 23-26 may have formed thereinone more niches or through-going slots. In the embodiment of FIGS. 1-6,front bank 23 has two through-going slots 27 and rear bank 24 has twothrough-going slots 28. Preferably, rear recess 12 is bisected by planeP and has bilateral symmetry about plane P.

In the embodiments of FIGS. 1-6, crown recess 12 is longer than rearrecess 21 and has the same width as rear recess 21. Alternatively, crownrecess 12 is wider than rear recess 21. Alternatively, crown recess 12is narrower than rear recess 21. Alternatively, crown recess 12 has thesame length as rear recess 21. Alternatively, rear recess 21 is longerthan crown recess 12.

Outside of recesses 12 and 21, shell 10 is divided into zones of unequalelevation delimited from and connected to neighboring zones by slopedbanks.

A first zone 100 of highest elevation includes a forehead region 35which is rectangular, roughly rectangular, or trapezoidal, and sweepingregion 39.

In the embodiment of FIGS. 1-6, forehead region 35 extends from frontedge 29 toward crown recess 12 and is partially defined by banks 36, 37,38. Bank 38 slopes toward and abuts front bank 15 of crown recess 12.The top edge of forehead region 35 may be the same width as floor 14.Forehead region 35 may broaden from bank 38 in the direction of frontedge 29.

First zone 100 extends from forehead region 35 along front edge 29 andforms sweeping region 39 which sweeps across the shell from left edge 30to right edge 31. Rear recess 21 is located in sweeping region 39 offirst zone 100. Sweeping region 39 can be viewed as consisting of aright temporal wing 101 and a left temporal wing 102, with rear recess21 located in the rear of the helmet where right temporal wing 101 andleft temporal wing 102 meet. Right temporal wing 101 begins at the rightedge 31 of shell 10 and sweeps across the right side of shell 10 aboveearholes 48, 49 associated with the right earflap 34 toward rear recess21. Left temporal wing 102 begins at the left edge 30 of shell 10 andsweeps across the left side of shell 10 above earholes 48, 49 associatedwith the left earflap 33 toward rear recess 21. First zone 100, foreheadregion 35, sweeping region 39, right temporal wing 101 and left temporalwing 102 strengthen shell 10 by imparting additional resistance toflexing, and thereby improve the strength and durability of the helmet.

First zone 100 may include provisions for attaching loopstraps to shell10. The provisions may include recesses 103 formed in first zone 100 inwhich holes may be formed for mounting loopstraps to shell 10 by meansof screws and T-nuts.

A second zone 110 of lower elevation than first zone 100 is partiallysurrounded by first zone 100. Crown recess 12 is located in second zone110. Crown recess 12 may be oriented lengthwise along the plane P andextend from the edge of first zone 100 and/or forehead region 35 to theedge of first zone 100, or the edge of second zone 10, or moreparticularly the border between first zone 100 and second zone 100.Second zone 110 rises to meet first zone 100 at points adjacent to rearbank 16 of crown recess 12. Second zone 110 may have through-going holesor slots for ventilation. In the embodiment shown in FIGS. 1-6, secondzone 110 has elongated ventilation slots 44, 45 alongside banks 40, 41,respectively, in the right area of the helmet, and elongated ventilationslots 46, 47 alongside banks 42, 43, respectively, in the left area ofthe helmet. Ventilation slots 44, 45 are not co-linear, and definebetween them an angle greater than 90 degrees. Similarly, ventilationslots 46, 47 are not co-linear, and define between them an angle greaterthan 90 degrees.

A third zone 120 of lower elevation than first zone 100 is adjacent tosweeping region 39 of first zone 100. Third zone 120 is joined tosweeping region 39 by bank 11, and is joined to fourth zone 130 by bank13. Third zone 120 sweeps across the shell from left earflap 33 to rightearflap 34. Third zone 120 may have one or more through-going ear holesassociated with the left earflap 33 and right earflap 34. In theembodiment of FIGS. 1-6, each earflap is associated with two earholes,specifically, a convex earhole 48 and a concave earhole 49. Raised reararea, or back shelf, 50 in third zone 120 is bounded on the left edgeand right edge by banks sloping down to third zone 120; bounded on thetop by the bank 11 sloping down from sweeping region 39 of first zone100 to third zone 120; and bounded on the bottom by the bank 13 slopingdown from third zone 120 to fourth zone 130. Raised rear area, or backshelf, 50 imparts greater flexural resistance to shell 10. Through-goingelongated ventilation slots 58 may be formed in raised rear area 50.Through-going elongated ventilation slots 59 may be formed in third zone120.

A fourth zone 130 of lowest elevation than third zone 120 is adjacent tothird zone 120. Fourth zone 130 is bounded by bottom edge 32 and sweepsacross shell 10 from left earflap 33 to right earflap 34.

Turning now to the shock absorbers and floating shell plates disposed inshell recesses, as shown for example in FIGS. 17-19, a floating shellplate 50 for crown recess 12 according to an embodiment of the subjecttechnology is composed of a single sheet of material suitable for use ina helmet shell, for example, ABS, polycarbonate, reinforced fiberglass,or carbon fiber composite. Floating shell plate 50 may be manufacturedby injection molding or thermoforming. Floating shell plate 50 is sizedand shaped to serve as a lid or cover over crown recess 12. Floatingshell plate 50 has a body 51 and tabs extending from body 51 at theperiphery of body 51. In an embodiment of the present technology,floating shell plate has two tabs 52 positioned at a top edge of body 51and two tabs 53 positioned on the opposite (bottom) edge of the body 51.Body 51 is curved to conform to the outer curvature of the profile ofsecond zone 100 shell 10. Tabs 52, 53 are sized and adapted to engagewith niches or slots 19, 20 in the walls of crown recess 12.Accordingly, tabs 52, 53 extend downwardly at an angle from theperiphery of body and each tab may terminate in a bent end which isadapted to be inserted into slots 19, 20 in the walls of crown recess12, thereby removably retaining the floating shell plate over crownrecess 12. Alternatively, each tab 52, 53 may terminate in a straightend. Left and right edges of body 51 may be formed with a plurality ofsegments 54 connected by angled transition portions 55 to formcrenulations or crenulated edges along the left and right of body 51. Tofurther secure the connection of floating shell plate 50 to shell 10,the body 51 may be provided with through-going holes 56 for receiving ascrew or bolt connecting plate 50 to cushion 70, or to shell 10, or toboth. Floating shell plate 50 may have a thickness of 0.090 inches orapproximately 0.090 inches. Floating shell plate 50 may have one or moreholes 56 or elongated slots 57 formed therein.

As shown for example in FIGS. 27-28, a shock absorbing cushion 70 forcrown recess 12 according to an embodiment of the subject technology iscomposed of a single flexible sheet of TPU material by molding orthermoforming. According to an embodiment of the subject technology,cushion 70 is sized and adapted to nest and fit closely within crownrecess 12 of the shell.

Domes are formed in a base sheet 73 of TPU material and are distributedover a coverage area to provide shock absorption between floor 14 andfloating shell plate 50. Base sheet 73 is formed in a curved shape tomatch the curvature of floor 14. Domes may be oriented outwardly (i.e.in the direction away from floor 14), or inwardly (toward floor 14,thereby forming cups). In an embodiment of the subject technology, rows74 of aligned, alternating domes 71 and cups 72 are formed in base sheet73 (only one such row is numbered in the figures). Preferably, thesequence of domes and cups in a row is the inverse of the sequence inthe neighboring row. Other arrangements of domes and/or cups in basesheet 73 is within the scope of the subject technology, for example, alldomes, all cups, rows of cups alternating with adjacent rows of domes.Holes 75 may be formed in the base sheet 73 for attachment of cushion 70to shell 10. The holes 75 may be defined and surrounded by a thickenedarea 76 to strengthen the part. Holes 76 may be formed in the base sheet73 for attachment of plate 50 to cushion 70, or to shell 10, or both.Holes 75, 76 may be defined and surrounded by a thickened area tostrengthen the part. The edges of the cushion 70 may be formed asthickened ridges 80, 81 interrupted by cutouts. In an embodiment of thesubject technology, four cutouts 78, 79 are formed in the ridges, twocutouts 78 on a top edge of the pad and two cutouts 79 on the opposite,bottom edge. Cutouts 78, 79 coincide with tabs 52, 53 to permit tabs 52,53 to engage with niches or slots 19, 20, respectively. In an embodimentof the subject technology, four ridges 80, 81 are formed at the edges ofbase sheet 73. Preferably, ridges 80, 81 are sized so as not to protrudeabove the surface defined by plate 50. Ridges 80 at the top edge andbottom edge of base sheet 73 may be formed with a triangularcross-section, the peak 82 of the triangle at the point of contactbetween ridges 80 and base sheet 73, the base 83 of the triangleoriented away from base sheet 73 and floor 14. In that embodiment, oneside 84 of the triangle is formed to conform with the slope of theadjacent bank 15 or 16 so that when cushion 70 assembled to crown recess12, side 84 closely contacts bank 15 or 16. Additionally, base 83 may beformed to conform with the curvature of floating shell plate 50 so thatthe curvature is smoothly continued from plate 50 over base 83.Preferably, the length of ridges 80 is less than the distance betweentabs 52, 53, to define a gap between the left and right ends of ridges80 and the inner edges of tabs 52, 53, so that floating shell plate 50is permitted to move in a direction tangential to the surface of shell10.

As best seen in FIG. 8, cushion 70 is assembled to crown recess 12 sothat the peaks of any cups 72 are contacting floor 14 and base sheet 73is mostly suspended above floor 14, although base sheet 73 may contactfloor 14 at points where it is not supported by adjacent cups 72. In anembodiment in which cushion 70 has no cups and only domes, base sheet 73is contacting floor 14. Cushion 70 may be removably secured to shell 10by screws and T-nuts passing through holes 75 and corresponding holes infloor 14. Cutouts 78, 79 align with niches or slots 19, 20 so thatcushion 70 and base sheet 73 are not obstructing niches or slots 19, 20.As best seen in FIG. 9, crown floating shell plate 50 is assembled overcushion 70. Tabs 52, 53 are inserted into niches or slots 19, 20 viacutouts 78, 79 in cushion 70. The crenulations, holes 56 and/orelongated slots 57 may expose portions of cushion 70. Floating shellplate 50 is removably attached by a screw or bolt passing through holes56 connecting plate 50 to cushion 70, or to shell 10, or to both. In anembodiment in which floating shell plate 50 is removably attached tocushion 70 but not to shell 10, advantageously, a relatively large holemay be formed in floor 14 below the hardware (screw or bolt) connectingplate 50 to cushion 70, so that the hardware is not normally contactingfloor 14.

Rear recess 21 receives shock absorbing cushion 90 and floating shellplate 60, which are similar in form and function to shock absorbingcushion 70 and floating shell plate 50, respectively. As shown forexample in FIGS. 20-22, a floating shell plate 60 for rear recess 21according to an embodiment of the subject technology is composed of asingle sheet of polymer material suitable for use in a helmet shell, forexample, ABS, polycarbonate, reinforced fiberglass, or carbon fibercomposite. The floating shell plate 60 may be formed by injectionmolding or thermoforming. Floating shell plate 60 has a body 61 and tabs62, 63 extending from the body 61 at the periphery of the body. Floatingshell plate 60 is sized and shaped to serve as a lid or cover over rearrecess 21. In an embodiment of the present technology, floating shellplate has two tabs 62 positioned at a top edge of the body and two tabs63 positioned on the opposite, bottom, edge of the body. Body 61 iscurved to conform to, and continue, the outer curvature of the shellprofile of sweeping region 39 of first zone 100. Tabs 63, 63 are sizedand adapted to engage with the niches or slots 27, 28 in the walls ofthe rear recess 21. Accordingly, tabs 61, 62 extend downwardly at anangle from the periphery of body and each tab may terminate in a bentend which is adapted to be inserted into the slots 27, 28 in the banksof the rear recess 21, thereby removably retaining floating shell plate60 in rear recess 21. Alternatively, each tab 62, 63 may terminate in astraight end. Left and right edges of body 61 may be formed withsegments 64 connected by angled transition portion 65. To further securethe connection of floating shell plate 60 to shell 10, the body 61 maybe provided with through-going hole 66 for receiving a screw or boltconnecting plate 60 to cushion 90, or to shell 10, or to both. One ormore slots 67 may be formed in body 61. Floating shell plate 60 may havea thickness of 0.090 inches or approximately 0.090 inches. Floatingshell plate 60 may have one or more hole(s) 66 or elongated slots 67formed therein.

As shown for example in FIGS. 23-26, a shock absorbing cushion 90 forrear recess 21 according to an embodiment of the subject technology iscomposed of a single flexible sheet of TPU material by molding orthermoforming. According to an embodiment of the subject technology,cushion 90 is sized and adapted to nest and fit closely within rearrecess 21 of the shell. Domes are formed in a base sheet 93 of TPUmaterial and are distributed over a coverage area to provide shockabsorption between floor 22 and floating shell plate 60. Base sheet 93is formed in a curved shape to match the curvature of floor 22. Domesmay be oriented outwardly (i.e. in the direction away from floor 22), orinwardly (toward floor 22, thereby forming cups). In an embodiment ofthe subject technology, a row 94 of aligned, alternating domes 91 andcups 92 is formed in the forward edge of base sheet 93. A second row 86of domes is formed amid base sheet 93. A third row 87 of cups is formedin a rear edge of base sheet 93. Other arrangements of domes and/or cupsin base sheet 93 is within the scope of the subject technology, forexample, all domes, all cups, rows of cups alternating with adjacentrows of domes. Holes 95 may be formed in the base sheet 93 forattachment of cushion 90 to shell 10. The holes 95 may be defined andsurrounded by a thickened area 76 to strengthen the part. Holes 89 maybe formed in the base sheet 93 for attachment of plate 90 to cushion 90,or to shell 10, or both (more than one hole could be formed and used forthis purpose). Holes 89, 95 may be defined and surrounded by a thickenedarea to strengthen the part. The edges of the cushion 90 may be formedas thickened ridges 96, 97 interrupted by cutouts. In an embodiment ofthe subject technology, four cutouts 98, 99 are formed in the ridges,two cutouts 98 on a top edge of the pad and two cutouts 99 on theopposite, bottom edge. Cutouts 98, 99 coincide with tabs 62, 63 topermit tabs 62, 63 to engage with niches or slots 27, 28, respectively.In an embodiment of the subject technology, four ridges 80, 81 areformed at the edges of base sheet 93. Preferably, ridges 96, 97 aresized so as not to protrude above the surface defined by plate 60.Ridges 96 at the top edge and bottom edge of base sheet 93 may be formedwith a triangular cross-section, the peak 103 of the triangle at thepoint of contact between ridges 96 and base sheet 93, the base 104 ofthe triangle oriented away from base sheet 93 and floor 22. In thatembodiment, one side 105 of the triangle is formed to conform with theslope of the adjacent bank 23 or 24 so that when cushion 90 assembled torear recess 21, side 105 closely contacts bank 23 or 24. Additionally,base 104 may be formed to conform and continue with the curvature offloating shell plate 60 so that the curvature is smoothly continued fromplate 60 over base 104. Preferably, the length of ridges 96 is less thanthe distance between tabs 61, 62, to define a gap between the left andright ends of ridges 80 and the inner edges of tabs 61, 62, so thatfloating shell plate 50 is permitted to move in a direction tangentialto the surface of shell 10. The ridges 97 on the left and right edges ofcushion 90 may be formed with a relatively thick lower segment 106connected to a relatively thin upper segment 107 by an angled transitionportion, forming a shelf.

FIG. 8 in particular shows a helmet 1 according to the subjecttechnology with the floating shell plates removed, to show the assemblyof cushions 70, 90 to shell 10 in recesses 12, 21.

FIG. 14 shows a sectional rendering of shell 10, floating shell plates50, 60, cushions 70, 90, with an inner plate for a cheek supportattached to the right earflap.

FIG. 15 shows a partially exploded view of floating shell plates 50, 60with respect to shell 10. Cushion 70 is shown as installed in crownrecess 12.

In use in sports play, when helmet 1 is subjected to forces and blows onand around plate 50, a component of force normal (i.e. perpendicular) tothe surface of plate 50 compresses one or more of domes 71 and/or cups72, between plate 50 and floor 14, which compression is resilientlyresisted by the TPU material of cushion 70, domes 71 and/or cups 72. Andwhile the material of plate 50 is somewhat flexible, the curvature ofbody 51 of plate 50 gives it sufficient rigidity that the compressivenormal force is distributed over a number of domes 71 and/or cups 72. Acomponent of force tangential to the surface of plate 50 urges plate 50to move in the direction of the force. In response to the tangentialcomponent of force (i.e., the component parallel to the surface of plate50), plate 50 may move or slide, with consequent resilient deformationof cushion 70 and its base sheet 73 by the action of plate 50 and itsconnection to cushion 70.

After the force is removed, cushion 70 and its base sheet 73, domes 71and/or cups 72 resiliently rebound and return to their original shape,and plate 50 is restored to its original position. In this way, plate 50is resiliently movable independently of shell 10 when subjected toforceful blows, reacting in multiple directions to help betterdistribute the energy of an impact. In embodiments in which the lengthof ridges 80 is less than the distance between tabs 52, 53, to define agap between the left and right ends of ridges 80 and the inner edges oftabs 52, 53, floating shell plate 50 has more freedom of movement in thelateral or tangential direction, which is advantageous for this mode ofoperation.

Similarly, when helmet 1 is subjected to forces and blows on and aroundplate 60, a component of force normal (i.e. perpendicular) to thesurface of plate 60 compresses one or more of domes 91 and/or cups 92,between plate 60 and floor 22, which compression is resiliently resistedby the TPU material of cushion 90, domes 91 and/or cups 92. And whilethe material of plate 60 is somewhat flexible, the curvature of body 61of plate 60 gives it sufficient rigidity that the compressive normalforce is distributed over a number of domes 91 and/or cups 92. Acomponent of force tangential to the surface of plate 60 urges plate 60to move in the direction of the force. In response to the tangentialcomponent of force (i.e., the component parallel to the surface of plate60), plate 60 may move or slide, with consequent resilient deformationof cushion 90 and its base sheet 93 by the action of plate 60 and itsconnection to cushion 90.

After the force is removed, cushion 90 and its base sheet 93, domes 91and/or cups 92 resiliently rebound and return to their original shape,and plate 60 is restored to its original position. In this way, plate 60is resiliently movable independently of shell 10 when subjected toforceful blows, reacting in multiple directions to help betterdistribute the energy of an impact. In embodiments in which the lengthof ridges 96 is less than the distance between tabs 62, 63, to define agap between the left and right ends of ridges 96 and the inner edges oftabs 62, 63, floating shell plate 60 has more freedom of movement in thelateral or tangential direction, which is advantageous for this mode ofoperation.

Helmet 1 may have attached to shell 10 cheek supports, such as thosedisclosed in U.S. patent application Ser. No. 15/456,279, published asU.S. Patent Published Patent Application 2017/0291095, for “FootballHelmet with Cheek Supports,” the entire disclosure of which is herebyincorporated by reference, which is assigned to the assignee of thepresent application. The disclosed cheek supports, which may also beused in the present technology of helmet 1, consist of an outer brace,an inner plate, and cheek pads associated with the inner plate, all ofwhich are more particularly described in the incorporated pending patentapplication. FIGS. 83-90 show views of outer braces which may be used inhelmet 1, as alternatives to the outer braces described in theincorporated pending patent application. FIGS. 91-94 show views of innerplates which may be used in helmet 1, as alternatives to the outerbraces described in the incorporated pending patent application. FIGS.95-98 show views of cheek pads which may be used in helmet 1, asalternatives to the outer braces described in the incorporated pendingpatent application. The function, materials, dimensions and structure ofthe outer brace, inner plate, cheek pads which may be used in helmet 1are as described in the incorporated pending patent application. Whenhelmet 1 is worn by a football player, as more particularly described inthe incorporated pending patent application, the cheek pads are heldfirmly against the wearer's cheek to at least partially overlay the areaof the zygomatic bone. The cheek pads exert forces bearing against thewearer's cheek area to help retain the helmet 1 on the head duringsports play. The padding provided by the cheek pad also providesprotection to that area against collisions.

Helmet 1 has inner padding elements removably attached to the innersurface of shell 10 to provide further shock absorption, to help bettersize the helmet to the wearer, and for the comfort of the wearer. Innerpadding elements in helmet 1 include shock absorbing elements made ofTPU consisting of a base sheet of TPU with projecting hollow cones, suchas those described in U.S. Pat. No. 9,622,533 for “Single-layer paddingsystem,” the entire disclosure of which is hereby incorporated byreference, which is assigned to the assignee of the present application.The TPU elements are installed in contact with the inner surface ofshell 10.

FIGS. 67-70 show views of a TPU crown shock absorbing element that maybe installed in the helmet 1 of the subject technology, in the crownarea of helmet 1. According to the embodiment shown in FIGS. 67-70,crown TPU element 160 comprises a base sheet 161 having hollowfrusto-conical projections 162 (only one is numbered) extendingtherefrom and distributed over the coverage area to provide shockabsorption. Squared hollow cones 163 also provide shock absorption, andhave T-nuts at their distal ends for attaching the assembly to the innersurface of shell 10. Projections 162 may have closed distal ends (i.e.,the projections terminate in a surface which closes the upper end of theprojections), alternatively, some or all of projections 162 may haveopen distal ends. In either case, the distal ends of projections 162 and163 are slanted such that when installed, the distal ends overallconform to and closely contact the inner surface of shell 10. Crown TPUelement 160 is curved overall to closely contact the inner surface ofshell 10. Projections 162 and 163 may be each be connected to one ormore of its neighbors by connecting ribs 164 (only one is numbered).Connecting ribs 164 stabilize element 160 by tending to supportprojections 162 and 163 and tending to prevent projections 162 and 163from tipping or leaning when subjected to a shock or blow during sportsplay. Supported by ribs 164, projections 162 and 163 preferentiallycollapse in a resilient manner when subjected to shocks. Keyway 165 maybe formed in base sheet 161 for passage of a tube for inflation of aninflatable liner component. Keyway 165 may be formed with retainingprojections 166 to retain the inflation tube in keyway 165 duringassembly, as hereinafter described in connection with the description ofthe crown inflatable liner.

FIGS. 29-32 show views of a TPU shock absorbing element, particularly afront pad insert, that may be installed in the helmet 1 of the subjecttechnology, as hereinafter described.

FIGS. 29-32 show views of a TPU shock absorbing element which may beused in a front area of helmet 1, above the front edge 29 of the shell.This element may be used in conjunction with a front pad. FIGS. 34-35show views of a front pad, which is made of a resilient polymer materialsuch as EVA or slow-recovery EVA. The front pad includes recesses orthrough-going holes for receiving TPU cones of the front area TPU shockabsorbing element, so that the element and pad may be assembled togetherto form a composite TPU/EVA front shock absorbing element. FIGS. 36-37show views of the assembly of the element and pad. FIGS. 38-39 showviews of the composite front pad, complete with its soft padded comfortlayer.

As shown in FIGS. 29-32, TPU element 140 comprises a base sheet 141having hollow frusto-conical projections extending therefrom to provideshock absorption. In the embodiment of this element as shown, element140 comprises seven long cones 142 (only one is numbered), two shortcones 143, and two squared cones 144. Squared cones 144 have T-nuts attheir distal ends for attaching the assembly to the inner surface ofshell 10.

Turning specifically to the EVA pad, as shown in FIGS. 33-35, pad 145has a thick region 149 integrally formed with a thin region 150, therebya recess 146 is formed therebetween. Thin region 150 has formed thereinpassages or holes 147 (only one is numbered) for receiving long cones142. Passages 147 may pass all the way through thin region 150. Squareholes 148 are formed in thin region 150 for receiving squared cones 144.Thick region 149 may have passages or holes 151 (only one is numbered)to improve the resiliency of that region; in an alternative embodiment,thick region 149 is formed without holes to result in a stiffer pad.Passages 147 may be sized to provide a friction or interference fit withlong cones 142 such that long cones 142 fit snugly within passages 147.Pad 145 may be made of slow-recovery EVA having a hardness of 50 Shore“C”, or other foam or cushioning material suitable for the desiredapplication. Pad 145 is molded to have a contoured outer surface 152that nests within the inner surface of shell 10.

As shown in FIGS. 36-37, element 140 and pad 145 are assembled to formfront pad assembly 153. TPU element 140 is received in recess 146, longcones 142 are received in passages 147, and the flat ends of short cones143 abut the surface of thin region 150. As best seen in FIG. 37, in apreferred embodiment, long cones 142 extend through passages 147 suchthat the flat ends of long cones 142 form a substantially continuoussurface with pad outer surface 152. The ends of squared cones 144 andthe attached T-nuts are also exposed at surface 152 for attachment ofassembly 153 at the inner surface of shell 10. In a preferredembodiment, pad assembly 153 is enclosed in an envelope consisting of asoft comfort pad 154 on the side of the pad facing the wearer, and afabric backing 155 made of a material such as tricot on the side facingthe inner surface of shell 10. It will be appreciated that the flat endsof long cones 142 contact the inner surface of shell 10, or have onlythe thin fabric layer 155 between the flat ends and the inner surface.This composite structure provides an area of reinforced shock absorptionjust above the front edge of shell 10, coinciding with the assembly ofthin region 150 and TPU element 140, while higher up, the un-reinforcedthick region 149 performs similarly to a conventional EVA brow pad.Thus, the subject technology may include a composite front pad,comprising a molded TPU shock absorber having frusto-conical projectionsextending from a base sheet, mated with a pad of molded foam material,the frusto-conical projections being received snugly into openingsformed in the pad of molded foam material, the mated assembly fittedwith a soft padded comfort layer. The composite front pad is especiallywell suited for use in protecting against the most forceful and frequentblows sustained in a full-contact sport, such as the blows received onthe brow of a football helmet.

FIG. 40 shows a view of a lateral assembly of TPU shock absorbingelements that may be installed in the helmet 1 of the subjecttechnology, in the rear area of the helmet, and extending to the leftand right side areas of the helmet. FIGS. 41-43 show views of thecentral element of the assembly. FIGS. 44-45 show views of a top elementof the assembly. FIGS. 62-63 show views of a left wing of the assembly.FIGS. 49-51 show views of a right wing of the assembly.

Turning first to FIG. 40, lateral TPU assembly 170 is composed ofcentral TPU element 171, upper TPU element 172, right TPU element 173,and left TPU element 174. Elements 171, 172, 173, 174 may be formedintegrally, or formed separately and attached together. When formedintegrally, elements 171, 172, 173, 174 may be attached by living hingesof TPU material formed in the base sheet. When formed separately, eachof elements 171, 172, 173, 174 may be formed with a tab at the peripheryfor bonding to corresponding tab of the neighboring element. The tabsmay be bonded by any suitable means known to the art, includingadhesives and plastic welding. Central TPU element 171 is connected toupper TPU element 172, right TPU element 173, and left TPU element 174,as shown.

Each of elements 171, 172, 173, 174 is generally similar inconstruction, in that each is formed of a TPU base sheet 176, 177, 178,179, respectively, having hollow frusto-conical projections extendingtherefrom to provide shock absorption, 180, 181, 182, 183, respectively,(only one projection is numbered in each element). One or more of theseTPU elements may be formed with a fence of TPU material, composed ofbase sheet material and running along one or more edges of the elements.In the embodiment of FIGS. 40-51, central TPU element 171, right TPUelement 173, and left TPU element 174 each has such a fence of TPUmaterial, numbered respectively 184, 185, 186, formed along the edgeswhich face toward the open bottom of shell 1. Central TPU element 171may be formed with keyway 187 for passage of a valve for an inflatableliner as hereinafter described. Central TPU element 171 may be composedof a central middle portion 190, a central right lobe 188, and centralleft lobe 189, integrally formed out of a single piece of TPU material.Central right lobe 188 and central left lobe 189 are each connected tocentral middle portion 190 by a bridge of base sheet material. Each ofelements 171, 172, 173, 174 may have one or more squared hollowprojections 191 with a T-nut at the distal end for attachment to theinner surface of shell 10.

FIGS. 102-104 show views of a TPU shock absorbing element having a densedistribution of cones, which may be used in a top area of helmet 1.

FIG. 16 shows a schematic rendering of TPU shock absorbing elements ashereinabove described installed on the inner surface of shell 10.

The inner padding elements of helmet 1 may include inflatable elements,which are particularly well adapted to custom-size helmet 1 to thewearer. In general construction, inflatable elements according to thesubject technology are formed of bottom sheet and a top sheet ofsuitable material which may be TPU material. Recesses or pockets areformed in the top sheet. The recesses or pockets may contain pads;however, some recesses may be devoid of pads. The bottom sheet is bondedto the top sheet to seal the recesses or pockets and thereby formpressure-containing cells, which may be pressurized through a valve influid communication with the cells. Each of these inflatable elements orliners is inflated through a valve disposed in a tube, the tubeextending through openings in the associated mobility layer, associatedTPU shock absorbing element, and shell, so that the liners areinflatable from outside of helmet 1. FIGS. 55-59 show views of aninflatable lateral liner which may be used in helmet 1, which isinstalled in the rear area of the helmet and extends laterally left andright. FIGS. 74-75 show views of an inflatable crown liner which may beused in helmet 1, which is installed in the crown area of the helmet.FIGS. 99-101 show plan views of pads of resilient polymer foam materialwhich may be disposed in the inflatable cells of the crown inflatableliner, having shapes which conform to the shapes of the respectivecells.

Turning now to FIGS. 55-60, inflatable lateral liner 200 comprises a topsheet 201 of a suitable thin, flexible material such as TPU, vinyl, orthe like, bonded to a bottom sheet 202 of such material. The overallliner 200 is sized and shaped to approximately overlie lateral TPUassembly 170. Pockets are formed in the top sheet 201, which when bondedto the bottom sheet 202 form air-containing cells 203, 204 (only one ofeach is numbered) in the liner 200. Cells 203, 204, are distributed overthe area of the top sheet 201 facing the wearer, to provide comfort andshock absorption. Certain of the cells are inflatable, and are linkedtogether by air-conducting passages 212 (only four are numbered) topermit passage of inflating air into the inflatable cells. Optionally,certain cells are non-inflatable and are not connected by passages. In apreferred embodiment, the non-inflatable cells are arranged at the topedge of liner 200 (i.e. the edge in the direction of the crown of helmet1). Cells 203, 204, are preferably shaped so that they interlock asshown. In the illustrated embodiment, cells 203 are shaped as truncatedtriangles with concave sides, and cells 204 are crescent-shaped, thusenabling interlocking of the cells as shown. Other interlocking shapes,or non-interlocking shapes, could be used for the cells of liner 200. Avalve assembly 205 is connected in fluid communication with one of theinflatable cells of liner 200 via inflation tube 206. Tube 206 passesthrough an opening in bottom sheet 202 to enable inflation of the cellto which it is connected, and the entire set of inflatable cells whichare interconnected by passages 206. The opening is sealed around tube206 for airtightness and to anchor tube 206 to bottom sheet 202. Liner200 may be formed with a tab 207 having a hook-and-loop fastener 208 ontop sheet 201. When liner 200 is installed, tab 207 is tucked behindlateral TPU assembly 170 and fastener 208 is mated with the oppositehook-and-loop fastener adhered to the inner surface of shell 10.Preferably, valve assembly 205 consists of valve 211, which may be aconventional needle-inflation valve, positioned within a mating tube210. Mating tube 210 is mated to the distal end of inflation tube 206,and has a flange, which is covered on the shell-facing side withhook-and-loop fastener material. When installed, the distal end ofmating tube 210 is inserted into a through-going hole in shell 10, andthe flange is removably attached via its hook-and-loop fastener materialto the opposite hook-and-loop fastener adhered adjacent to thethrough-going hole.

Turning now to FIGS. 74-75, inflatable crown liner 240 is similar inconstruction to inflatable lateral liner 200. Inflatable crown liner 240comprises a top sheet 241 of a suitable thin, flexible material such asTPU, vinyl, or the like, bonded to a bottom sheet 242 of such material.The overall liner 240 is sized and shaped to approximately overlie crownTPU element 160. Pockets are formed in the top sheet 241, which whenbonded to the bottom sheet 242 form air-containing cells 243, 244, 252(only one of each is numbered) in the liner 240. Cells 243, 244, 252,are distributed over the area of the top sheet 241 facing the wearer, toprovide comfort and shock absorption. Certain of the cells areinflatable, and are linked together by air-conducting passages 246 (onlytwo are numbered) to permit passage of inflating air into the inflatablecells. In the embodiment shown, all cells of liner 240 are inflatable.Optionally, certain cells are non-inflatable and are not connected bypassages. Cells 243, 244, are preferably shaped so that they interlockas shown. In the illustrated embodiment, cells 243 are shaped astruncated triangles with concave sides, cells 244 are crescent-shaped,and cell 252 is circular, thus enabling interlocking of the cells asshown. Other interlocking shapes, or non-interlocking shapes, could beused for the cells of liner 240. A valve assembly 245 is connected influid communication with one of the inflatable cells of liner 240 viainflation tube 247. Tube 247 passes through an opening in bottom sheet242 to enable inflation of the cell 252 to which it is connected, andthe entire set of inflatable cells which are interconnected by passages246. The opening is sealed around tube 246 for airtightness and toanchor tube 247 to bottom sheet 242. Preferably, valve assembly 245consists of valve 251, which may be a conventional needle-inflationvalve, positioned within a mating tube 250. Mating tube 250 is mated tothe distal end of inflation tube 247, and has an integral flange, whichis covered on the shell-facing side with hook-and-loop fastenermaterial. When installed, the distal end of mating tube 250 is insertedinto a through-going hole in shell 10, and the flange is removablyattached via its hook-and-loop fastener material to the oppositehook-and-loop fastener adhered adjacent to the through-going hole.

FIGS. 10-13 show a helmet 1 according to an embodiment of the presenttechnology. FIGS. 10 and 13 show the placement of TPU shock absorbingelements and cheek supports, without the mobility layers and inflatableelements of the present technology (all of which are hereinafterdescribed).

In addition to the TPU shock absorbing elements, the inner paddingelements of helmet 1 may include mobility layers (also referred to asmobility liners) disposed between the inflatable liner elements and theTPU shock absorbing elements. Mobility layers according to the presenttechnology may be composed of ethylene-vinyl acetate (EVA) polymer or asimilar resilient polymer, with a backing of black loop fabric to matewith hook pads in a hook-and-loop fashion, the hook pads disposed on theother liner elements to removably attach the layers to said elements andwithin helmet 1. FIGS. 52-54 show views of a lateral mobility layer thatis shaped and sized to be interposed between the lateral assembly of TPUshock absorbing elements and the lateral inflatable liner. FIGS. 71-73show views of a crown mobility layer that is shaped and sized to beinterposed between the the crown shock absorbing element and the crowninflatable liner. A mobility layer according to the subject technologyincorporates bumps or domes on the side facing the TPU shock absorbingelement or elements to reduce the area of contact and thereby reducefrictional forces between the mobility layers and the TPU shockabsorbing elements. Alternatively, the bumps or domes could be disposedon the side facing the inflatable liner elements, or could be disposedon both sides of the mobility layer facing both the shock absorbingelements and inflatable liner elements. The interposition of themobility layers between the TPU shock absorbing elements and theinflatable liner elements permits relative movement between the TPUshock absorbing elements and the inflatable liner elements when a shockforce or blow is received on the helmet during sports play, whichassists in protecting the head from being subjected to forces and frombeing accelerated by said forces. In this manner, the helmet shell 10and attached TPU shock absorbing elements can move to some extent in arotational or sliding direction without imparting the same amount ordegree of movement to the inflatable liner elements and the wearer'shead, which is in contact with the inflatable liner elements.

Turning now to FIGS. 52-54, for improved performance, a lateral mobilitylayer or lateral mobility layer 220 is provided, to be disposed orsandwiched between liner 200 and lateral TPU assembly 170. Lateralmobility layer 220 is molded from a suitable material, for example, EVApolymer. Mobility layer 220 is molded to have domes 221 (only one isnumbered) distributed over one side of the liner and rising above thesurface 224 of that side; the other side is backed with a fabriccovering 222. A through-going hole 223 is formed in layer 220 to allowpassage of valve assembly 205 and inflation tube 206. Mobility layer 220is sized and shaped to approximately overlie lateral TPU assembly 170.The domed side of liner 220 has adhered to it hook-and-loop fastenerpads 225 (only one is shown), which preferably are sparsely distributed.

As shown in FIGS. 61-62, mobility layer 220 is assembled to inflatablelateral liner 200 by mating fasteners 209 on bottom sheet 202 of liner200 with fabric cover 222 of liner 220. When assembled, domes 221 faceaway from liner 200 (best seen in FIG. 62).

As best seen in FIGS. 63-64, the assembly of lateral liner 200, mobilitylayer 220, and lateral TPU assembly 170 results in a sandwich ofmobility layer 220 between lateral liner 200 and lateral TPU assembly170. Domes 221 of mobility layer 220 face toward and contact lateral TPUassembly 170 and provide a gap or clearance between the surface 224 ofmobility layer 220 and the elements of lateral TPU assembly 170. Thedomes 221 thereby reduce the contact area between surface 224 andlateral TPU assembly 170, and thereby reduce the transmission ofrotational or sliding force and movement of shell 10 and its attachedlateral TPU assembly 170 to mobility layer 220 and lateral liner 200.

Turning now to FIGS. 72-73, according to the subject technology, a crownmobility layer or crown mobility layer 260 is provided, to be disposedor sandwiched between crown inflatable liner 240 and crown TPU element160. Crown mobility layer 260 is similar in form to lateral mobilitylayer 220 and is molded from a suitable material, for example, EVApolymer. Mobility layer 260 is molded to have domes 261 (only one isnumbered) distributed over one side of the liner and rising above thesurface 264 of that side; the other side is backed with a fabriccovering 262. A through-going hole or cutaway 263 is formed in layer 260to allow passage of valve assembly 245 and inflation tube 247. Mobilitylayer 260 is sized and shaped to approximately overlie crown TPU element160. The domed side of liner 260 has adhered to it hook-and-loopfastener pads 265 (only one is numbered), which preferably are sparselydistributed. Holes 266 may also be provided in liner 260 to provideaccess to the T-nuts affixing crown TPU element 160 to shell 10.

FIGS. 76-77 show views of the assembly of the crown inflatable liner240, crown mobility layer 260, and crown TPU shock absorbing element160. The inflation tube 247 of the crown inflatable liner 240 extendsthrough openings in the crown mobility layer and crown TPU element 160(through keyway 165) and is retained by keyway retaining projections166. A valve assembly is assembled to the end of the tube, including anannular rim lined with hook-and-loop material for securing the valveassembly to the inner surface of shell 10, so the valve remains in itsplace at an opening in shell 10 for inflation.

Turning now to FIGS. 99-101, the cells of lateral inflatable liner 200and crown inflatable liner 240 may contain pads of foam material, forexample, Omalon foam, to provide additional cushioning performance.Preferably, the pads are shaped to fit their cells, for example, pad 230for crescent cells 204, 244; pad 231 for circular cell 252; and pad 232for triangular cells 203, 243.

A face guard 150 may be removably attached to shell 10. Face guard 150may be in the form of a cage of metal wire, titanium wire, steel wire,or aluminum wire, and which may be coated overall with a polymercoating. FIGS. 105-128 show front and left-side views of various faceguard designs which may be used in helmet 1 according to the subjecttechnology, according to the wearer's needs and playing position.

Face guard 150 may be attached above front edge 29 of shell 10 by atwist-release mount such as that disclosed in U.S. Pat. No. 8,146,178,or in U.S. patent application Ser. No. 29/616,447, the entire disclosureof both of which are hereby incorporated by reference, both of which areassigned to the assignee of the present application. FIGS. 78-82 showviews of a twist-release mount which may be used in helmet 1.

Face guard 150 may be attached to shell 10 at the left edge 30 and rightedge 31 by conventional loop straps attached to shell 10 with screws,bolts, or T-nuts. The loop straps may be attached to shell 10 with apartial-turn faceguard mounting such as those disclosed in U.S. Pat. No.8,819,871 for “Helmet with partial turn faceguard mounting,” the entiredisclosure of which is hereby incorporated by reference, which isassigned to the assignee of the present application. Alternatively, inplace of conventional loop straps, face guard retainers may be used,such as those disclosed in co-pending U.S. patent application Ser. No.15/380,508 for “Improved Helmet Faceguard Retaining Device,” the entiredisclosure of which is hereby incorporated by reference, which isassigned to the assignee of the present application.

While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles. It will also beunderstood that the present invention includes any combination of thefeatures and elements disclosed herein and any combination of equivalentfeatures. The exemplary embodiments shown herein are presented for thepurposes of illustration only and are not meant to limit the scope ofthe invention.

What is claimed is:
 1. A football helmet comprising: a plastic shelladapted to receive and protect the head of a wearer; the shell having afront region, a crown region, a rear region, a left side region, a rightside region, an inner surface and an outer surface; a crown recessformed in shell and associated with the crown region; a first slotformed in the shell and associated with the crown recess; a crown shockabsorbing pad in the crown recess and removably connected to the shell;a crown shell plate removably attached to the crown shock absorbing padand having a first tab formed therein; the first tab engaging the firstslot; and a rear recess formed in shell and associated with the rearregion; a second slot formed in the shell and associated with the rearrecess; a rear shock absorbing pad in the rear recess and removablyconnected to the shell; a rear shell plate removably attached to therear shock absorbing pad and having a second tab formed therein; thesecond tab engaging the second slot.
 2. The helmet of claim 1 whereinthe crown shock absorbing pad is composed of a single sheet of TPUhaving domes formed in the single sheet to provide shock absorption. 3.The helmet of claim 1 wherein the rear shock absorbing pad is composedof a single sheet of TPU having domes formed in the single sheet toprovide shock absorption.
 4. The helmet of claim 1 wherein the crownrecess has a first bank and a second bank; the first slot is formed inthe first bank and a third slot is formed in the second bank, the crownshell plate further comprises a third tab; and the third tab engages thethird slot.
 5. The helmet of claim 4 wherein the first bank and secondbank are on opposite sides of the crown recess and are joined by a floorof the crown recess.
 6. The helmet of claim 1 wherein the rear recesshas a first bank and a second bank; the second slot is formed in thefirst bank and a third slot is formed in the second bank, the rear shellplate further comprises a third tab; and the third tab engages the thirdslot.
 7. The helmet of claim 6 wherein the first bank and second bankare on opposite sides of the rear recess and are joined by a floor ofthe rear recess.
 8. A helmet comprising: a plastic shell adapted toreceive and protect the head of a wearer; the shell having a frontregion, a crown region, a rear region, a left side region, a right sideregion, an inner surface and an outer surface; a liner associated withthe inner surface, the liner comprising a shock absorbing element, aninflatable liner element, and a mobility layer disposed between theshock absorbing element and the inflatable liner element, the mobilitylayer having a plurality of raised elements formed therein, theplurality of raised elements separating the shock absorbing element fromthe mobility layer thereby forming a gap between the shock absorbingelement and the mobility layer, enabling relative movement of theinflatable liner with respect to shock absorbing element.
 9. The helmetof claim 8 wherein the shock absorbing element is composed of a sheet ofTPU having a plurality of hollow projections formed therein for shockabsorption.
 10. The helmet of claim 8 wherein the plurality of raisedelements is a plurality of domes.
 11. A football helmet comprising: aplastic shell adapted to receive and protect the head of a wearer; theshell having a front region, a crown region, a rear region, a left sideregion, a right side region, an inner surface and an outer surface; acomposite front pad associated with the inner surface of the shell andpositioned over a front edge of the shell to at least partially overliethe brow of a wearer; the composite front pad comprising a shockabsorbing element and a brow pad; the shock absorbing element in theform of a sheet of plastic material having a first plurality of hollowprojections formed therein; the brow pad formed of a resilient polymermaterial and having a plurality of passages formed therein; theplurality of passages receiving the first plurality of hollowprojections.
 12. The helmet of claim 11 wherein the shock absorbingelement comprises a second plurality of hollow projections formed in thesheet of plastic material, the second plurality of hollow projectionsabutting the brow pad but not received in passages.
 13. The helmet ofclaim 11 wherein the brow pad comprises a thick region and a thinregion, the plurality of passages being formed in the thin region, thethick region and thin region being integrally formed thereby a recessbetween the thin region and the thick region, the shock absorbingelement being received in the recess.
 14. The football helmet of claim 1further comprising: a liner associated with the inner surface, the linercomprising a first shock absorbing element, an inflatable liner element,and a mobility layer disposed between the first shock absorbing elementand the inflatable liner element, the mobility layer having a pluralityof raised elements formed therein, the plurality of raised elementsseparating the first shock absorbing element from the mobility layerthereby forming a gap between the first shock absorbing element and themobility layer, enabling relative movement of the inflatable liner withrespect to first shock absorbing element; and a composite front padassociated with the inner surface of the shell and positioned over afront edge of the shell to at least partially overlie the brow of awearer; the composite front pad comprising a second shock absorbingelement and a brow pad; the second shock absorbing element in the formof a sheet of plastic material having a first plurality of hollowprojections formed therein; the brow pad formed of a resilient polymermaterial and having a plurality of passages formed therein; theplurality of passages receiving the first plurality of hollowprojections.